EP2512789B1 - Verfahren und vorrichtung zur dosierung eines linsenformungsmaterials in einer gussform - Google Patents

Verfahren und vorrichtung zur dosierung eines linsenformungsmaterials in einer gussform Download PDF

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Publication number
EP2512789B1
EP2512789B1 EP10799007.9A EP10799007A EP2512789B1 EP 2512789 B1 EP2512789 B1 EP 2512789B1 EP 10799007 A EP10799007 A EP 10799007A EP 2512789 B1 EP2512789 B1 EP 2512789B1
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EP
European Patent Office
Prior art keywords
contact lens
mold
forming material
dosing
male
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Not-in-force
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EP10799007.9A
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English (en)
French (fr)
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EP2512789A1 (de
Inventor
Matthias Braun
Axel Heinrich
Peter Hagmann
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Novartis AG
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Novartis AG
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/00009—Production of simple or compound lenses
    • B29D11/00413—Production of simple or compound lenses made by moulding between two mould parts which are not in direct contact with one another, e.g. comprising a seal between or on the edges
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/00009—Production of simple or compound lenses
    • B29D11/00038—Production of contact lenses
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/00009—Production of simple or compound lenses
    • B29D11/00038—Production of contact lenses
    • B29D11/00125—Auxiliary operations, e.g. removing oxygen from the mould, conveying moulds from a storage to the production line in an inert atmosphere
    • B29D11/00134—Curing of the contact lens material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/00009—Production of simple or compound lenses
    • B29D11/0048—Moulds for lenses
    • B29D11/00538—Feeding arrangements

Definitions

  • the invention relates to a method of dosing a contact lens forming material into a contact lens mold and an apparatus therefor.
  • a lens forming material e.g., a polymer or prepolymer solution, such as a polymer or prepolymer solution containing water
  • a lens forming material is introduced into a female mold half, the casting mold is closed by the respective male mold half and then the lens forming material is polymerized and/or cross-linked with ultraviolet (UV) light.
  • UV ultraviolet
  • Suitable polymers formed by photochemical polymerization of suitable prepolymers include polymers based on polyvinyl alcohols (PVA) or silicone hydrogels (SiHy) as well as based on polyethylene glycols (PEG).
  • PVA polyvinyl alcohols
  • SiHy silicone hydrogels
  • PEG polyethylene glycols
  • lens forming materials which include a solvent, for example silicone hydrogels (SiHy), which may contain alcohols, such as propanol or isopropanol or other, as a solvent.
  • Solvents for example propanol, however, are typically volatile.
  • a solvent containing lens forming material is dosed into the female mold half of the opened mold, at least a portion of the solvent evaporates before the mold is closed again. Due to the reduced amount of solvent the lens forming material changes its properties, which, after the lens forming material has been polymerized or cross-linked may result in streaks or other defects or undesirable property changes on or in the formed lens.
  • Such defects such as streaks, if located in the vision area of the lens, may be intolerable so that the lens must be rejected after inspection.
  • residues of lens forming material having a reduced solvent content may deposit at the tip of the dosing unit and influence the accuracy of the next dosing process in an adverse manner.
  • volatile solvents are very often easily inflammable and/or explosive so that special provisions must be taken if such materials are used.
  • US 4,680,149 discloses a spin casting method for used in the manufacture of contact lenses.
  • a method of producing optical lenses from polymerizable resinous materials is disclosed.
  • US 2004/0041287 discloses a method of manufacturing composite photochromic optical lenses that have the ability to darken when exposed to certain wavelengths of light
  • DE 37 12 128 discloses a method of forming plastic optical articles using molds having a molding surface which is particularly scratch-resistant and has enhanced heat transfer properties.
  • the volatile solvent cannot evaporate as it occurs with the mold halves in an open state.
  • the solvent remains in the contact lens forming material so that the properties thereof remain unchanged and the formation of defects such as streaks during polymerization and/or cross-linking of the contact lens forming material is avoided.
  • no special provisions must be taken to prevent inflammation or explosion of the volatile solvent.
  • the male and female mold halves may be held in a closed or nearly closed position. This allows advantageous process variants which will be discussed hereinafter.
  • the mold cavity is connected with a dosing channel comprising an inner section connected with the mold cavity and an outer section which extends through a guide sleeve which holds the male and female mold halves.
  • the dosing channel is accessible from the outside of the contact lens mold and dosing of the contact lens forming material is accomplished through this dosing channel.
  • the dosing is accomplished with a dosing needle which, for the dosing process, is attached to and sealingly received by the dosing channel
  • air contained in the mold cavity is expelled through at least one venting opening which is provided in the guide sleeve and which is connected with the mold cavity by an annular channel which is from about 5 ⁇ m to about 15 ⁇ m wide from a first annular shoulder enclosing the first molding surface of the female mold half to a second annular shoulder enclosing the second molding surface on the male mold half.
  • the time required for the dosing may be reduced and optimized.
  • dosing pressures of about 0.1 bar to about 5 bar above ambient pressure may be suitable.
  • the contact lens forming material is dosed into the mold cavity with the male and female mold halves being held in the nearly closed position.
  • the male and female mold halves are then completely closed during the polymerization and/or cross-linking of the contact lens forming material.
  • the closing of the male and female mold halves may be accomplished actively by the use of an activator, and/or passively, due to the attracting forces the contact lens forming material exerts on the mold halves during shrinkage.
  • the contact lens forming material is dosed into the mold cavity with the male and female mold halves being held in the (completely) closed position.
  • additional contact lens forming material may be introduced through the dosing channel into the mold cavity in order to compensate for shrinkage of the contact lens forming material.
  • the additional contact lens forming material may be actively injected, or it may be sucked into the mold cavity automatically due to an underpressure which builds up because of the shrinkage process.
  • the method of dosing into the mold cavity with the male and female mold halves being held in the closed or nearly closed position may be accomplished with practically all contact lens forming materials. It is, however, of particular advantage with contact lens forming materials which comprise a volatile solvent. Accordingly, in an embodiment of the invention a silicone hydrogel (SiHy) material comprising propanol as a solvent is used as the contact lens forming material.
  • SiHy silicone hydrogel
  • An apparatus for carrying out the method according to the invention in order to form a contact lens from a contact lens forming material is specified by the features of the independent apparatus claim.
  • the guide sleeve is provided with at least one venting opening which is in connected (i.e. in communication) with the mold cavity.
  • the at least one venting opening in the guide sleeve may comprise a number of venting slots which are distributed about its circumference of the guide sleeve and are connected with the mold cavity.
  • the invention is exemplified with reference to the manufacture of contact lenses in a so-called full mold process.
  • a large number of contact lenses is manufactured with reusable contact lens molds in a closed loop process.
  • a number of reusable contact lens molds which each comprise associated male and female mold halves, are usually arranged in side by side configuration in worktrays which are transported consecutively through the individual treatment stations of a production line.
  • the treatment stations comprise a dosing station, in which a contact lens forming material, usually a prepolymer or polymer solution, is metered into the contact lens mold, a polymerization station, in which the contact lens forming material is polymerized and/or cross-linked.
  • the contact lenses are then removed from the contact lens molds and transported through an extraction, rinsing and washing station, a hydration station, a lens inspection station, a packaging station, and a sorting and storage station.
  • the present invention relates to the dosing of the contact lens forming material into a contact lens mold, in which a contact lens is formed.
  • Suitable polymers formed by photochemical polymerization of suitable prepolymers include, for example, polymers based on polyvinyl alcohols (PVA) or silicone hydrogels (SiHy) as well as based on polyethylene glycols (PEG).
  • Fig. 1 shows an axially sectioned view of a typical contact lens mold, which is generally designated with reference numeral 1.
  • the contact lens mold 1 comprises a female mold half 2 with a first molding surface 5 and a male mold half 3 with a second molding surface 6.
  • the first and second molding surfaces 5, 6 delimit (enclose) a mold cavity 4, which corresponds in shape to that of the contact lens to be manufactured.
  • the female and male mold halves 2, 3 are held circumferentially in a sliding fit of a guide sleeve 7 which allows a relative axial movement of the female and male mold halves 2, 3.
  • the female and male mold halves 2, 3 are shown in a nearly closed position.
  • a first annular shoulder 51 enclosing the first molding surface 5 of the female mold half 2 and a second annular shoulder 61 enclosing the second molding surface 6 on the male mold half 3 are axially spaced from each other a certain distance, which may amount to, e.g., from about 5 ⁇ m to about 15 ⁇ m.
  • the guide sleeve 7, in which the female and male mold halves 2, 3 are held in a sliding fit, not only serves for an axial guidance of the mold halves 2, 3 but also constitutes a circumferential sealing for the two associated mold halves 2, 3, which is substantially gas-tight.
  • a dosing channel 8 For injecting a contact lens forming material P into the nearly closed contact lens mold 1 there is provided a dosing channel 8, which extends about radially in vicinity of the first and second annular shoulders 51, 52 which constitute separation planes of the contact lens mold 1.
  • the dosing channel 8 comprises an inner section 82 which is connected with the mold cavity 4 and an outer section 87 which extends radially through the guide sleeve 7.
  • the dosing channel 8 is adapted to sealingly receive a tip of a dosing needle, which is indicated in Fig. 1 at reference numeral 11.
  • the contact lens forming material P in particular a polymer or prepolymer solution containing a volatile solvent is injected into the mold cavity 4, e.g., with a pressure of, for example, about 0.1 bar to about 5 bar above ambient pressure.
  • air which is contained in the mold cavity 4 is expelled through at least one venting opening 10 in the guide sleeve 7.
  • venting opening 10 in the guide sleeve 7 is in contact (i.e. connected) with the mold cavity 4.
  • this contact is established by an annular channel 9 which results from the separation distance between the first and second annular shoulders 51, 61.
  • This separation distance amounts to, e.g. from about 5 ⁇ m to about 15 ⁇ m, and is wide enough to enable entrapped air to be expelled, but prohibits the injected contact lens forming material P from flowing out of the mold cavity 4.
  • shrinkage of the contact lens forming material P Upon polymerization and/or cross-linking of the contact lens forming material P within the mold cavity 4 there may occur shrinkage of the contact lens forming material P. This shrinkage can be compensated for by the two mold halves 2, 3 moving into the completely closed position. The closing of the mold halves 2, 3 may be accomplished actively with the aid of actuators, such as, e.g., piezoelectric elements, and/or it may be accomplished passively by attraction forces between the contact lens forming material P and the molding surfaces 5, 6.
  • actuators such as, e.g., piezoelectric elements
  • the example of a contact lens mold depicted in Fig. 2 is of a very similar construction to that of Fig. 1 . Therefore, like components are designated with like reference numerals.
  • the contact lens mold is generally designated with reference numeral 21 and comprises a female mold half 2 with a first molding surface 5 and a male mold half 3 with a second molding surface 6.
  • the female and male mold halves 2, 3 are circumferentially guided in the sliding fit of a guide sleeve 7.
  • the female and male mold halves 2, 3 are shown in a completely closed position, in which the two molding surfaces 5, 6 delimit the mold cavity 4.
  • First and second annular shoulders 51, 61 are abutting each other.
  • Dosing of the contact lens forming material is accomplished into mold cavity 4 of the closed contact lens mold 21 through a dosing channel 8, which extends about radially in vicinity of the annular shoulders 51, 61.
  • the dosing channel 8 has an inner section 82 which extends in the female mold half 2 and an outer section 87 which extends through the guide sleeve 7.
  • a dosing needle may be inserted into the dosing channel 8 which is adapted to provide a sealing fit.
  • At least one venting channel 29 is provided in the female mold half 2 which opens into the mold cavity 4.
  • the venting channel 29 is connected with at least one venting opening 10 in the guide sleeve 7.
  • the cross-section of the venting channel is selected such, that air may easily be expelled but the flow of dosed contact lens forming material out of the mold cavity 4 is prohibited.
  • Fig. 3 shows the contact lens mold 21 of Fig. 2 in the state, in which the mold cavity 4 is completely filled with contact lens forming material P.
  • the dosing channel 8 still contains a certain amount of contact lens forming material P, which may be sucked into the mold cavity 4 due to an overpressure which is created as the contact lens forming material P shrinks during the polymerization and/or cross-linking process.
  • the contact lens mold 21 is opened in order to remove the formed contact lens and to continue the processing thereof.

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  • Engineering & Computer Science (AREA)
  • Health & Medical Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Ophthalmology & Optometry (AREA)
  • Mechanical Engineering (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Eyeglasses (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)

Claims (11)

  1. Verfahren zur Dosierung eines Kontaktlinsenbildungsmaterials in eine Kontaktlinsengiessform (1; 21) hinein, welches das Dosieren einer abgemessenen Menge eines Kontaktlinsenbildungsmaterials (P) enthaltend ein flüchtiges Lösungsmittel in eine Giessformkavität (4) hinein umfasst, die von einer männlichen Giessformhälfte (3) mit einer zweiten Formungsfläche (6) und einer weiblichen Giessformhälfte (2) mit einer ersten Formungsläche (5) der Kontaktlinsengiessform (1; 21) umschlossen ist, wobei die Giessformkavität (4) im geschlossenen Zustand der Kontaktlinsengiessform der Form der herzustellenden Kontaktlinse entspricht, wobei das Kontaktlinsenbildungsmaterial (P) anschließend zur Bildung einer Kontaktlinse polymerisiert und/oder vernetzt wird, und wobei die Dosierung des Kontaktlinsenbildungsmaterials (P) in die Giessformkavität (4) hinein durchgeführt wird, während die männlichen und weiblichen Giessformhälften (2, 3) im Wesentlichen gasdicht miteinander in Verbindung stehen,
    wobei die Giessformkavität (4) mit einem Dosierkanal (8) verbunden ist, der einen mit der Giessformkavität (4) verbundenen Innenabschnitt (82) und einen sich radial durch eine Führungshülse (7), welche die männlichen und weiblichen Giessformhälften (2, 3) hält, erstreckenden Aussenabschnitt (87) umfasst, wobei der Dosierkanal (8) von der Außenseite der Kontaktlinsengiessform (1; 21) her zugänglich ist und wobei die Dosierung des Kontaktlinsenbildungsmaterials (P) durch diesen Dosierkanal (8) hindurch erfolgt,
    wobei das Dosieren mit einer Dosiernadel (11) durchgeführt wird, die für den Dosiervorgang am Dosierkanal (8) befestigt ist und dichtend von diesem aufgenommen ist, wobei während des Dosierens des Kontaktlinsenbildungsmaterials (P) in der Giessformkavität (4) enthaltene Luft durch mindestens eine Entlüftungsöffnung (10), die in der Führungshülse (7) vorgesehen ist, ausgestossen wird, und welche Entlüftungsöffnung mit der Giessformkavität (4) über einen ringförmigen Kanal (9) verbunden ist, der ungefähr 5 µm bis ungefähr 15 µm breit ist von einer ersten ringförmigen Schulter (51), welche die erste Formungsfläche (5) der weiblichen Giessformhälfte (2) umschliesst, zu einer zweiten ringförmigen Schulter (61), welche die zweite Formungsfläche (6) auf der männlichen Giessformhälfte (3) umschliesst.
  2. Verfahren nach Anspruch 1, wobei die männlichen und weiblichen Giessformhälften (2, 3) in einer geschlossenen oder beinahe geschlossenen Position gehalten werden.
  3. Verfahren nach Anspruch 1 oder 2, wobei der Dosierkanal (8) radial in der Nähe einer Trennebene der männlichen und weiblichen Giessformhälften (2, 3) vorgesehen ist und sich durch die Führungshülse (7) hindurch erstreckt, welche die männlichen und weiblichen Giessformhälften (2, 3) hält.
  4. Verfahren nach einem der vorangehenden Ansprüche, wobei die Dosierung des Kontaktlinsenbildungsmaterials (P) mit Druck oberhalb von Umgebungsbedingungen durchgeführt wird.
  5. Verfahren nach Anspruch 4, wobei das Kontaktlinsenbildungsmaterial (P) in die Giessformkavität (4) hinein mit einem Druck oberhalb von Umgebungsbedingungen von ungefähr 10.000 Pa bis ungefähr 500.000 Pa eingespritzt wird.
  6. Verfahren nach einem der Ansprüche 2-5, wobei das Kontaktlinsenbildungsmaterial (P) in die Giessformkavität (4) hinein dosiert wird, wobei die männlichen und weiblichen Giessformhälften (2, 3) in der beinahe geschlossenen Position gehalten werden, und wobei die männlichen und weiblichen Giessformhälften (2, 3) während der Polymerisation und/oder Vernetzung des Kontaktlinsenbildungsmaterials (P) vollständig geschlossen werden.
  7. Verfahren nach einem der Ansprüche 2-6, wobei das Kontaktlinsenbildungsmaterial (P) in die Giessformkavität (4) hinein dosiert wird, wobei die männlichen und weiblichen Giessformhälften (2, 3) in der vollständig geschlossenen Position gehalten werden, und wobei während der Polymerisation und/oder Vernetzung des Kontaktlinsenbildungsmaterials (P) zusätzliches Kontaktlinsenbildungsmaterial (P) zum Ausgleichen von Schwund in die Giessformkavität (4) eingeführt werden kann.
  8. Verfahren nach einem der vorangehenden Ansprüche, wobei ein Silikon-Hydrogel-Material (SiHy), das Propanol als Lösungsmittel umfasst, als Kontaktlinsenbildungsmaterial (P) verwendet wird.
  9. Vorrichtung zur Bildung einer Kontaktlinse aus einem Kontaktlinsenbildungsmaterial (P), umfassend eine Kontaktlinsengiessform (1; 21), die männliche und weibliche Giessformhälften und eine Führungshülse (7) aufweist, wobei das Linsenformungsmaterial in eine Giessformkavität (4) hinein dosiert wird, die von ersten und zweiten Formungsflächen (5, 6) der männlichen Giessformhälfte (3) und der entsprechenden weiblichen Giessformhälfte (2) der Kontaktlinsengiessform (1; 21) umschlossen ist, wobei die Giessformkavität (4) im geschlossenen Zustand der Giessform der Form der herzustellenden Kontaktlinse entspricht, wobei die männliche Giessformhälfte (3) und die weibliche Giessformhälfte (2) verschiebbar in der Führungshülse (7) gehalten werden, die eine beinahe gasdichte Abdichtung für die in Verbindung stehenden männlichen und weiblichen Giessformhälften (2, 3) bildet, und wobei die Vorrichtung weiterhin einen Dosierkanal (8) umfasst, der sich im Wesentlichen radial von der Giessformkavität (4) und durch die Führungshülse (7) hindurch erstreckt, wobei der Dosierkanal dazu ausgelegt ist, die Spitze einer Dosiernadel (11) dichtend aufzunehmen,
    wobei die Giessformkavität (4) mit einem Dosierkanal (8) verbunden ist, der einen mit der Giessformkavität (4) verbundenen Innenabschnitt (82) und einen sich radial durch die Führungshülse (7) hindurch erstreckenden Aussenabschnitt (87) umfasst, wobei der Dosierkanal (8) von der Außenseite der Kontaktlinsengiessform (1; 21) her zugänglich ist, und ferner umfassend
    mindestens eine Entlüftungsöffnung (10), die in der Führungshülse (7) vorgesehen ist und die über einen ringförmigen Kanal (9) mit der Giessformkavität (4) verbunden ist, der zwischen einer ersten ringförmigen Schulter (51), welche die erste Formungsfläche (5) der weiblichen Giessformhälfte (2) umschließt, und einer zweiten ringförmigen Schulter (61), welche die zweite Formungsfläche (6) auf der männlichen Giessformhälfte (3) umschließt, gebildet wird, wenn sich die weiblichen und männlichen Giessformhälften in der beinahe geschlossenen Position befinden, wobei der ringförmige Kanal (9) eine Breite von ungefähr 5 µm bis ungefähr 15 µm von der ersten zur zweiten ringförmigen Schulter (51, 61) in der beinahe geschlossenen Position aufweist.
  10. Vorrichtung nach Anspruch 9, wobei die Führungshülse (7) mit mindestens einer Entlüftungsöffnung (10) versehen ist, die mit der Giessformkavität (4) verbunden ist.
  11. Vorrichtung nach Anspruch 10, wobei die mindestens eine Entlüftungsöffnung eine Anzahl von Entlüftungsschlitzen (10) umfasst, die entlang des Umfangs der Führungshülse (7) verteilt sind und mit der Giessformkavität (4) verbunden sind.
EP10799007.9A 2009-12-17 2010-12-16 Verfahren und vorrichtung zur dosierung eines linsenformungsmaterials in einer gussform Not-in-force EP2512789B1 (de)

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US28747409P 2009-12-17 2009-12-17
PCT/EP2010/069936 WO2011073329A1 (en) 2009-12-17 2010-12-16 Method of dosing a lens forming material into a mold

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EP2512789A1 EP2512789A1 (de) 2012-10-24
EP2512789B1 true EP2512789B1 (de) 2018-05-16

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US (1) US9050761B2 (de)
EP (1) EP2512789B1 (de)
CN (1) CN102695601B (de)
HU (1) HUE039910T2 (de)
MY (1) MY161647A (de)
SG (2) SG181663A1 (de)
WO (1) WO2011073329A1 (de)

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CN104708763B (zh) * 2013-12-11 2017-03-01 均豪精密工业股份有限公司 制镜系统及镜片的制备方法
CN104647701A (zh) * 2015-02-16 2015-05-27 杭州清渠科技有限公司 一种基于流动注塑的透镜制备装置
JP2017013117A (ja) * 2015-07-03 2017-01-19 株式会社日伸電工 成形用金型、成形方法及び成形品
US20180056613A1 (en) 2016-08-30 2018-03-01 Novartis Ag Process for dispensing a contact lens forming fluid material
CN111531770B (zh) * 2020-03-31 2021-11-19 厦门晶华视康医疗器械有限公司 一种透镜成型的模具

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MY161647A (en) 2017-04-28
EP2512789A1 (de) 2012-10-24
HUE039910T2 (hu) 2019-02-28
WO2011073329A1 (en) 2011-06-23
CN102695601A (zh) 2012-09-26
US9050761B2 (en) 2015-06-09
SG10201408249YA (en) 2015-02-27
CN102695601B (zh) 2016-01-06
SG181663A1 (en) 2012-07-30
US20110147956A1 (en) 2011-06-23

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